SPAWAR_PRESENTATION_FINAL_2014-04-12-MCV-SPAWAR_Industry_Day_Brief-F.1.1_(1).pptx

Mobile Communications Vehicle (MCV) Overview DISTRIBUTION STATEMENT C: Distribution authorized to U.S. Government Agencies and their contractors.

Presented at:

Industry Day for Solicitation

QMAA-HM-140013-D

15 April 2014

Presented by:

Laura Rolinger MCV Chief Engineer SPAWARSYSCEN Atlantic

Space and Naval Warfare Systems Center Atlantic

Agenda Design Overview Break for Pilot MCV Viewing Key Requirements Technical Documentation Testing Inspection Warranty Additional Deliverables Heuristic Feedback Schedule Key Takeaways

Design Overview

Design Overview Vehicle Platform F-350 Lariat Crew Cab (or equal) with gas engine Converted to SUV-style body with metal construction Payload capacity: 2,800 lbs min. remaining after modifications Air spring system Exterior Modifications Antenna platform SATCOM antenna mounting plate Antenna cable signal entry panels (Qty 2) Curbside signal entry panel Tie down points to secure vehicle for transport Uniform and professional paint finish

Pilot MCV Exterior

Antenna Platform

Design Overview (cont.)

Interior Modifications Seat configuration Privacy partition Custom equipment racks Equipment mounts and trays Professional finish

Additional Equipment Power generation system Payload batteries Security alarm Emergency lights/sirens Cable trays Lighting Navigation screen camera interface

Interior Layout

Desired Cable Tray Layout

Pilot MCV Viewing Key differences between Pilot and Production vehicles:

Model year of base vehicle Metal rear Hatch-style rear door Functional middle row doors Cable trays Faux windows on rear SUV section are not required Equipment not included under this contract:

Networking and communications equipment Power distribution system Ports on signal entry panels Plastic cover on antenna platform

Pilot MCV Viewing (cont.)

Features to note:

Antenna platform layout Interior layout Space constraints Necessity for tight tolerances in the design Necessity for accessibility to equipment and cabling for integration and maintenance Ergonomics of operator area Interior finish

Break for Pilot MCV Viewing

Key Requirements:

Technical

Overarching Technical Requirements Reliability – Mission critical system deployed worldwide High workmanship standard Maintainability Most maintenance performed by certified military personnel Design should minimize frequency, duration, and complexity of maintenance activities Operational life of 10-years – Parts need to be available Uniformity across fleet and adherence to documented design is critical – Tolerance of 0.1” on metal fabrications Safety – Rigor in design is required to ensure modifications do not induce safety hazards Operating temperature: -32o C to 49o C (-25o F to 120o F)

Modified Vehicle 2015 Ford F-350 4x4 Crew Cab, or equivalent Must be gas powered (not diesel) Most powerful OEM engine available Lariat trim level Appearance/Construction Rear section shall be enclosed so that vehicle appears similar to a Ford Expedition Doors: 6 side and 1 rear hatch Windows: 4 side windows (1st and 3rd rows) and windshield only Single rear wheel configuration All-metal body, to include rear section “Class A” exterior finish, black paint with no metallic flake

Modified Vehicle (cont.)

Payload capacity remaining after modifications:

Front: 1,000 lbs min.

Rear: 1,800 lbs min. (OEM axle will need to be modified/replaced) Transportable on enclosed semi-trailer, C-5, and C-17 Front and rear air spring suspension system Run-flat tires rated for normal driving at 81 mph Vehicle engine, exhaust, and cooling system shall be optimized to tolerate extended idle times of ten (10) hours at an ambient temperature reaching 49oC Modifications shall be done In Accordance With (IAW) the Body Builders Layout Book and OEM guidelines

Additional Vehicle Interfaces Navigation screen camera interface Allows viewing of rear camera at any time Accepts additional video inputs from Government installed cameras Security alarm Emergency lighting and PA/siren

Prohibited/Disabled Features Disable and remove Vehicle tracking system Rear air bags OEM seat belts Disable the back-up alarm The receiver for the following systems shall be disabled such that a user cannot re-enable the systems:

Keyless Entry Remote Start Bluetooth Tire Pressure Monitoring System (TPMS) Sensors shall NOT be installed in tires

Antenna Platform and Signal Entry Size: 139” x 50” min.

Profile: 1”-2” from roof at closest point Water drainage No discharge above side windows SATCOM antenna mounting plate and support structure Two signal entry points 12”x15” stainless steel Removable and water tight

Curbside Signal Entry Panel Curbside rear “window” area at accessible height Water tight Rear plate:

Removable Dimensions: 20” x 9.5” min Inset 6” at closest point Vertical orientation Door:

Flush mounted Match vehicle trim Combination lock DISTRIBUTION STATEMENT C: Distribution authorized to U.S. Government Agencies and their contractors.

Side View of CSEP Shape

CSEP

Door Contoured to Vehicle Rear Plate 6” 9.5”

Equipment Racks and Work Surfaces Racks 1 and 2 Shape dictated by vehicle and Government installed equipment Carpeted panels on faces Racks 3, 4, and 5 Standard 19” rack shape, 20” deep, min. 20 RU high Even spaced holes on rails Easily removable Operator work surface Printer bench DISTRIBUTION STATEMENT C: Distribution authorized to U.S. Government Agencies and their contractors.

Front Rear Dimensions are Critical Operator Compartment

Operator Seat Seat, seatbelt, and anchoring shall comply with all DOT/FMVSS safety standards for passenger vehicles Integrated seat belt Independent safety testing required Adjustments:

Forward/aft 4.5 inches in each direction Pivot 360o, locking every 45o minimum Operator must be able to access each rack and work surface while sitting in the seat with a seat belt fastened Integrated and storable writing table Operators will be sitting in the vehicle for up to 10 hrs, so comfort is a high priority

Auxiliary HVAC Required for heating and cooling of the rear compartment with ducting to the operator area and equipment racks Minimum capacity:

Cooling: 32,000 BTU Heating: 30,000 BTU Operator accessible controls: Thermostatic and fan speed Power sources Vehicle powered Shore powered via 120 VAC (desired) Components cannot be visible on exterior of vehicle Available space on interior of vehicle is limited

Payload Batteries Type: Dry cell, air transport certified Voltage: 24 VDC Capacity: 684 AH at 10-hr rate, min.

Discharge/recharge Cycles: 400 to 80% capacity, min.

Location: Under vehicle (preferred) or as depicted in layout Aftermarket lighting shall be powered directly from the payload battery bank Jump-start capability for the vehicle battery shall be provided from a payload battery

Electrical safety is very important in the battery box design and installation

Power Generation and Charging System Minimum capacity:

Vehicle power: 8 kW at engine idle (idle control module allowed) Battery power: 3.5 kW Output:

120 VAC for Government installed equipment Charging for payload batteries Electromagnetic Interference (EMI) must be minimized Power system must be reliable since it is a single point of failure

Electromagnetic Interference Protection To minimize electromagnetic signals escaping from the operator compartment, the following measures shall be taken:

Copper mesh shall be affixed to interior of body Nickel-based EMI coating shall be sprayed onto interior of body Radio Frequency (RF) and Infrared (IR) attenuation film shall be applied to both rear windows and the privacy partition All racks and electrical circuits shall be grounded to the vehicle frame with no more than 0.2 Ohms resistance between grounding points

Other Interior Features Privacy partition Sturdy enough to mount equipment < 5 lbs Pass-through door accessible from both sides Bulkhead mounting plates Cable trays – Open ladder style Keyboard/mouse trays under operator work surface Flat panel display mount Center console equipment mount Interior trim Black vinyl flooring in rear Black carpeted walls and panels

Quality and Uniformity Quality and Uniformity are Key Quality Vehicles will be rejected for workmanship issues All components shall be new Like assemblies shall be physically and functionally interchangeable Uniformity Designs shall be documented and placed under configuration management All vehicle shall be built IAW the approved design Production/integration shall be repeatable and consistent across all vehicles

Documentation

Required Documentation Verification Cross Reference Matrix (VCRM) Due with proposal Contains verification method for each requirement Drawings Includes Conceptual, Production, and As Built Drawings Product/Level III detail required for modifications and custom fabrications/assemblies Standards

ASME Y14.5

SPAWARSYSCEN Atlantic MCV Drawing Package Standard Operating Procedure (SOP) Government will own data rights to drawings

Required Documentation (cont.)

Structural Analysis Includes Tie Down, Antenna Platform, and GD 20-20 Mounting Plate Support Performed by Professional Engineer registered in the U.S.

Test Plans/Reports Includes First Production Vehicle (FPV) specific, Final Acceptance and Inspection, and Verification Artifacts Plans shall include test procedures mapped to requirements, test equipment with calibration certifications, and test facilities Reports shall include data collected during test, an analysis of the data, pass/fail determination for each requirement, and deviations from the test plan

Required Documentation (cont.)

Training Includes training syllabus, training materials, and training video Content: start-up, operation, shut-down, and maintenance Maintenance Documentation Includes Servicing and Parts Catalog and Maintenance Schedule Program Management/Administrative Includes meeting minutes, status reports, and schedule

Testing

First Production Vehicle (FPV) Testing High Temperature/AC Electrical Generator System Execute MIL-STD-810G, Method 501.5, Procedure II high temperature test Run AC Electrical Generator System at full load Measure interior ambient and surface temperatures Transportability Verify MCV can be loaded/secured/unloaded on an enclosed semi-trailer (110” H x 102” W) on a 16 ft ramp at a 15o angle Tie Down Provisions Test IAW with MIL-STD-209K Road Test At full payload capacity, test high speed, acceleration, unimproved roads, fuel economy, breaking, and turning radius

All Vehicles AC Electrical Generator System Includes full load testing from payload batteries and generator Water Spray Test all sides and undercarriage IAW MIL-STD-810G, Method 506.5, Procedure II Pre-Service Inspection Inspect IAW TMC RP 803 – Pre-Service Vehicle Inspection Road Test Test IAW TMC RP 803 – Pre-Service Vehicle Inspection Vocational Functionally test all equipment, systems, and components IAW manufacturer’s operating instructions

Inspection

Inspection In-Process Inspections The Government reserves the right to witness all in-process production activities and testing events Video or photographs shall include pictures showing the assembly of all major subassembly components, such as, but not limited to body mounting, rear hatch installation, copper mesh installation, and GD 20-20 support structure Final Inspection The MCV shall be complete in every respect and pre-inspected for compliance with all requirements prior to submitting to the Government for inspection Inspection of the first production MCV shall be videotaped or recorded by digital photographs

Warranty

Warranty Requirements “Bumper-to-Bumper” warranty for entire system Duration: 3 years or 36,000 miles Includes labor, parts, shipping costs, towing, and travel Single POC available 24/7 to address claims OEM vehicle warranty issues in U.S. and Canada Repair arranged at OEM Certified facility within 24 hrs of claim Government must be able to accompany MCV at all times On-site repairs in U.S. and Canada Repair team on-site within 48 hrs Shipment of parts/material only Delivery in U.S. or Canada within 48 hrs of claim Advance planning and coordination with suppliers and subcontractors is critical for meeting warranty response times

Additional Deliverables

Additional Deliverables Equipment Racks 1-5 with printer bench and operator work surface – 60 days prior to FPV delivery Will be used by Government to finalize design of communications and networking equipment integration prior to MCV delivery Spares Up to the equivalent of three (3) systems of spare parts/equipment Does not include base OEM vehicle Note: Custom parts shall be available for purchase for 10 years On-Site Technical Support Three (3) days of on-site technical support in Charleston, SC

Heuristic Feedback

Heuristic Feedback Strong background in systems engineering and production processes is required to ensure:

Adherence to requirements Sound engineering design Well documented design that meets the Government’s Technical Data Package Requirements Configuration management of documentation and hardware Repeatability of manufacturing and integration processes Ability to produce like parts and integrated vehicles Adherence to workmanship and quality standards Sound and thorough testing practices

Heuristic Feedback (cont.)

Body/frame mounting Body to frame should be isolated using the same isolation materials as cab and meet Body Builder Guidelines Rear SUV conversion hatch needs to be properly welded and bonded to truck to prevent stress cracks Special parts may be required for axle/wheel compatibility Warranty agreements need to be made with equipment suppliers and subcontractors to ensure the Prime’s warranty agreement with the Government can be fulfilled Excessive heat from the exhaust system can transfer through the floor if not properly insulated

Heuristic Feedback (cont.)

Operating temperature requirements should be considered when selecting wiring, adhesives, and components OEM trained electrical technicians should be used when modifying or making connections to OEM wiring to prevent induced electrical issues that can be difficult to identify Electrical grounds should be tied to a common point when possible with no more than 0.2 Ohms resistance between grounding points Struts on rear hatch need to be able to support the additional weight of a metal window to prevent sagging Ensure water that may collect on antenna platform does not drain near front windows

Heuristic Feedback (cont.)

Paint after modifications are complete to ensure uniformity Sheet metal screws, self tapping screws, and nylon insert locknuts are not suitable since they cannot be removed and replaced during maintenance Tie downs need to have sufficient stiffness to prevent bending when chains are tightened for transport The curbside SEP’s handle should be shaped/sized to provide a sufficient gripping surface to open the door in icy conditions Adequate time should be allocated for test and inspection events to allow for rework and retest to ensue delivery dates are met

Schedule

Technical Review and FPV Delivery Schedule DISTRIBUTION STATEMENT C: Distribution authorized to U.S. Government Agencies and their contractors.

Contract Award (CA) Post Award Conference (CA +7 BD) Preliminary Design Review (CA +30 CD) Critical Design Review (CA +60 CD) Test Readiness Review (FPVI – 60 CD) FPV Delivery Testing, Inspection, and Acceptance Supporting documentation (drawings, test plans/reports, etc.) due prior to reviews per schedule in Product Description (PD) BD = Business Days CD = Calendar Days Target:

< 6 Months

Fleet Completion Schedule

Proposed schedule should be:

Best economic effort to deliver fleet quickly Achievable Not create unacceptable technical performance risk Deliveries Lots vice piecemeal preferred to reduce the number of inspection trips Deliver entire fleet of MCVs as quickly as possible

Quality is very important Workmanship Tolerances Uniformity across fleet High reliability Repeatability of production and integration processes Thoroughly documented design is required Rigorous testing is required Supportability Design with ease of maintenance in mind Be prepared to provide timely warranty support Safety: DOT/FMVSS, electrical, etc High level of Government involvement through inspections and design reviews

The Government desires MCVs that exhibits the following qualities:

Adheres to workmanship and quality standards Built to tolerances of approved Product-level drawings Reliable Easy to maintain Safe The Successful Offeror will have attributes to include:

Commercial vehicle modification experience Demonstrated production capability with repeatable processes Demonstrated ability to produce Product-level drawings Ability to support warranty requirements image4.jpeg image5.jpeg image6.jpeg image10.jpeg image11.emf image12.emf image13.emf image14.png image15.emf image16.jpeg image1.jpeg image2.jpeg